CHAPTER 13 TOLERANCES FOR PRECAST AND PRESTRESSED CONCRETE

13.1 General • Working dimension. The planned dimension of the

precast concrete component obtained from its basic
This chapter introduces the subject of tolerances as related
dimension, the necessary joint or clearance dimen­
to buildings and provides the designer with some of the basic
sions, and other adjustments.
tolerances that should be considered during the layout and
Draft. The taper given to features of a mold or form to
design of precast concrete struc­tures. This chapter is a cursory
allow the precast concrete piece to be removed from the mold
presentation of infor­mation that has been previously pub-
or form without damage. Draft can result in different feature
lished by PCI and reviewed by the precast concrete industry.
dimensions between the front and back of a piece.
Because of this, PCI documents (see References 1 through
Drawings. The following are typical terms used by the
4) that discuss the subject of tolerances more fully should be
precast/prestressed concrete industry:
specified in contract docu­ments and referred to when resolv-
• Shop drawings. (1) Collective term used for erec-
ing questions about tolerances.
tion drawings, production drawings, and hardware
13.1.1 Definitions details. (2) Diagrams of individual precast concrete
components and their connecting hardware, devel-
Bowing. An overall out-of-plane condition in which two
oped from information in the contract documents.
opposite edges of a component, such as a panel, fall in the
Shop drawings show information needed for both
same plane and the portion of the panel between the edges is
field assembly (erection) and manufacture (produc-
out of plane.
tion) of the precast concrete components.
Camber. (1) The out-of-plane translation of a point within
• Erection drawings. Drawings that show the rela-
the span of a prestressed component that occurs due to the net
tionship of the precast components and their connec-
  bending resulting from an eccentric prestressing force (not
13 including dimen­sional inaccuracies); (2) a built-in curvature.
tions in the erected structure and that provide nec-
essary information to properly erect and connect the
Camber is typically measured at midspan.
various components.
Connection. A device for the attachment of pre­cast con-
• Production drawings. A set of instructions in the
crete components to each other or to the structure to which it
form of diagrams and text that contain all of the
is attached. Connection design must account for the cumula-
information necessary for the manufacturer to pro-
tive effects of all allowed tolerance variations.
duce the precast concrete component. These docu-
Contract documents. General conditions, project speci-
ments are usually produced by or under the direction
fications, and drawings issued on behalf of the owner by the
of the precast plant engineering department or by an
design professionals of record (architect/engineer) and from
entity hired by the precast concrete manufacturer.
which the project erection drawings and production drawings
Flatness. The degree to which a surface approximates a
are developed.
plane (see smoothness). This toler­ance is most important in
Clearance. Interface space (distance) be­tween two compo-
wall and slab components.
nents. Clearance is normally speci­fied to allow for the effects
Flushness. The offset relationship of an embedded plate to
of product and erection tolerances and for anticipated move-
the surrounding concrete.
ment such as deflection, volume change movement, and the
Plumb. In a vertical line.
like.
Pretopped systems. A construction ap­proach, typically
Clear distance. The least distance between the surface of
used in the floor system of parking structures, in which the
the reinforcement and the referenced surface. The referenced
double-tee flange for the floor component is constructed to its
surface may be the form, adjacent reinforcement, embed-
final thickness in the plant, resulting in cast-in-place concrete
ments, concrete sur­face, or other surfaces.
topping not being required in the field.
Concealed surface. Surface not visible during normal use
Quality. The appearance, strength, durability, and dimen-
of the component.
sional conformance that is appropriate for the specific prod-
Deviation. The departure from an established reference
uct, its particular application, and its expected performance
point, line, plane, or surface measured in a direction that is
requirements. Quality also refers to the totality of features
perpendicular to the reference line, plane, or surface.
and characteristics of a product and on its ability to satisfy
stated needs.
Dimensions. The following are several differ­ent categories
Quality assurance (QA). All those planned or systematic
of dimensions relevant to precast concrete fabrication.
actions necessary to ensure that the final product or service
• Actual dimension. The measured dimension of the
will satisfy given requirements for quality and performance
precast concrete component after casting. The actual
of intended function. Typically, the quality assurance effort
or as-built dimension may differ from the working
will focus on the requirements of the overall project, thereby
dimension due to construction and material-induced
identify­ing the tolerance quality control requirements for
variations.
component fabrication.
• Basic dimension. The dimensions shown on the con-
Quality control (QC). Those planned actions that provide
tract drawings or called for in the specifica­tions. The
a means to measure and control the characteristics of com-
basic dimension applies to size, location, and relative
ponents and materials to pre­determined, quantitative criteria.
location. It may also be called the nominal dimension.
Relative alignment. The distance between two or more

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TOLERANCES FOR PRECAST AND PRESTRESSED CONCRETE
components in any plane, or the distance between adjacent
components, or the distance between a component and a
defined point or plane.
Setup. The process of preparing molds or forms for casting,
including installation of materials (reinforcement and hard-
ware) prior to the actual placing of concrete. The setup process
is second only to the mold or form construction in its import­
ance in the achievement of specified component tolerances.
Shrinkage. The volume change in concrete caused by drying
that normally occurs during its curing and initial life. The expected
shrinkage must be sub­tracted from the form setup dimensions to
deter­mine the as-cast dimensions of a component.
Smoothness. The absence of local irregularity or rough-
ness. It does not refer to the overall shape of the component.
Specially finished structural precast concrete. A com-
ponent fabricated using forms and techniques common to the
production of structural components and having specified
surface finishes that require uniformity and detailing more
demanding than the typical requirements for structural com-
ponents. See Chapter 14, Section 14.2.3 of this handbook for
PCI plant certification categories.
Sweep. An overall variation in a component’s horizon­tal
alignment. This can sometimes be caused by horizontally
eccentric prestress in narrow components.
Tipping. The offset relationship of an embedded plate
from one edge to another.
Tolerance. The specified permissible deviation from spec-
ified requirements such as dimensions, location, and align-
ment. Examples are:
• the permitted deviation from a basic dimension or
quantity, as in the length, width, and depth of a com-
ponent;
• the range of variation permitted in maintaining a
basic dimension, as in an alignment tolerance; and
• a permitted variation from location or alignment.
Tolerances, erection. Those allowable deviations in dimen-
sions of a component’s placement in the completed structure
required for acceptable layout and placement of precast con-
crete components after they are erected.
Tolerances, interfacing. Those allowable deviations in
dimensions associated with other materials or systems in
contact with or in close proximity to the precast concrete.
Tolerances, product. Those allowable deviations
in dimensions relating to individual precast concrete
components.
Warping. Twisting of a component, resulting in overall
out-of-plane curvature of surfaces character­ized by all edges
being non-parallel. Warping is most often a concern in panel
components, although it can be a concern in other types of
components, such as pretopped double-tees.
13.1.2 Purpose
Tolerances are normally established by economical and
practical production, erection, and interfacing consid-
erations, and are based on References 1 through 4. Once
established, they should be shown in the contract docu-
ments, and used in design and detailing of components and
connections. Architectural and structural concepts should
PCI DESIGN HANDBOOK/SEVENTH EDITION First Printing/CD-ROM Edition
CHAPTER 13
be developed with the practical limitations of dimensional
control in mind, as the tolerances will affect the dimensions
of the completed structure.
Tolerances are required for the following reasons:
• Structural — To ensure that the structural design
accounts for factors that are sensitive to variations in
dimen­sion and plumbness. Examples include eccen-
tric loadings, bearing areas, and locations of rein-
forcement and embedded items.
• Feasible — To ensure acceptable performance of
joints and interfacing materials in the finished struc-
ture.
• Visual — To ensure that the variations will be con-
trollable and will result in an acceptable-looking
structure.
• Economical — To ensure ease and speed of produc-
tion and erection.
• Legal — To avoid encroaching on property lines and
to establish a standard against which the work can be
compared.  
• Contractual — To establish an acceptability range 13
and also to establish responsibility for developing
and maintaining specified tolerances.
13.1.3 Responsibility
While the responsibility for specifying and main­taining
tolerances of the various elements of construction may vary
among projects, it is important that these responsibil­ities be
clearly assigned. The conceptual design phase of a precast
concrete project is the time to begin considering dimensional
control. The established tolerances or required performance
should fall within generally accepted industry ranges and
should not be made more restrictive than necessary.
Once the tolerances have been specified, and connections
that consider those tolerances have been designed, the pro-
duction and erection of the components must be organized to
ensure tolerance compliance.
A quality control program that emphasizes dimensional
control is necessary. Likewise, an erection quality assurance
program that includes a clear definition of responsibilities
will aid in ensuring that the products are assembled in accor-
dance with the specified erection tolerances.
Responsibility should include dimension verification and
adjustment, if necessary, of both precast concrete compo-
nents and any interfacing structural elements.
13.1.4 Tolerance Acceptability Range
Tolerances must be used as guidelines for acceptability
and not as limits for rejection. If specified toler­ances are met,
the product should be accepted. If not, the product may be
accepted if it meets any of the following criteria:
• Exceeding the tolerance does not affect the structural
integrity or architectural performance of the component.
• The component can be brought within tolerance by
structurally and architecturally satisfactory means.
• The total erected assembly can be modified to meet
all structural and architectural require­ments.
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 CHAPTER 13
13.1.5  elationships between Different
R restrictive tolerances may significantly increase costs; they
Tolerances
A precast concrete component is erected so that its primary
control surface is in conformance with the established erec-
tion and interfacing tolerances. The secondary control sur-
faces are generally not directly positioned during erection but
are controlled by the product tolerances. Thus, if the primary
control surfaces are within erection and interfacing toler-
ances, and the secondary surfaces are within product toler-
ances, the component is erected within tolerance. The result-
ing tolerance limit for the secondary surface may be the sum
of the product and erection tolerances.
Because tolerances for some features of a precast concrete
component may be additive, it must be clear to the erector
which are the primary control surfaces. If both primary and
secondary control surfaces must be controlled, provisions
for adjustment should be included. The accumulated toler-
ance limits may have to be accommodated in the interface
clearance. Surface and feature control requirements should
  be clearly outlined in the plans and specifications.
13 On occasion, the structure may not perform properly if the
tolerances are allowed to accumulate. Which tolerance takes
precedence is a question of economics. The costs associated
with each of the three tolerances must be evaluated, recog-
nizing unusual situations. This may include difficult erection
requirements, connections that are tolerance-sensitive, or
production requirements that are set by the available equip-
ment. Any special tolerance requirements should be clearly
noted in the contract documents.
It is important for the designer of record to be aware of
and take into consideration the tolerances of other building
materials and systems used in the project.5, 6, 7
13.2 Product Tolerances
13.2.1 General
Product tolerances are listed in the primary report of the
PCI Committee on Tolerances, Tolerance Manual for Precast
and Prestressed Concrete Construction, MNL-135-00.1 This
report contains a more complete discussion of tolerances and
should be referred to for more specific details, such as location
tolerances for inserts, voids, haunches, and corbels, and for
warping tolerances and local smoothness requirements. Toler-
ances are also presented more completely in three PCI publica-
tions, Manual for Quality Control for Plants and Production of
Structural Precast Concrete Products, MNL-116-99; Manual
for Quality Control for Plants and Production of Architec-
tural Precast Concrete Products, MNL-117-96; and Erectors’
Manual: Standards and Guidelines for the Erection of Precast
Concrete Products, MNL-127-99.2,3,4 The products included
are listed in Table 13.2.1 in this handbook. Discussion of the
more critical tolerances are given in following sections. The
values shown have become the consensus standards of the pre-
cast concrete industry, and these values are occasionally dif-
ferent from tolerances published by other organizations.6 More
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TOLERANCES FOR PRECAST AND PRESTRESSED CONCRETE
should not be specified unless absolutely necessary.
13.2.2 Overall Dimensions
Typical tolerances for most precast/prestressed concrete
products are given in Table 13.2.1. Architectural precast con-
crete panels have plan dimension tolerances that vary with
panel size from ± 1/8 in. for a dimension under 10 ft to ± 1/4 in.
for a dimension of 20 ft to 40 ft. The thickness tolerance for
top and bottom slabs (flanges) of box beams and hollow-core
units are dependent on the position of cores. Flange thickness
tolerances are not given for hollow-core units. Instead, mea-
sured flange areas cannot be less than 85% of the nominal
calculated area.
MNL-135-00 emphasizes that the recommended tolerances
are only guidelines. Different values may be applicable in
some cases, and each project should be considered individu-
ally. The designer should also make reference to applicable
building codes to establish possibly different tolerances for
certain products. For example, Section 1009.3.2 of Inter-
national Building Code 20068 requires that “the tolerance
between the largest and smallest riser height or between the
largest and smallest tread depth shall not exceed 0.375 in. in
any flight of stairs.” Other similar situations may exist.
13.2.3 Sweep or Horizontal Misalignment
Horizontal misalignment, or sweep, usually occurs as a
result of form and component width tolerances. It can also
result from prestressing with lateral eccentricity, which
should be considered in the design. Joints should be dimen-
sioned to accommodate such variations.
Sweep tolerances generally vary with the length of a unit,
for example, ± 1/8 in. per 10 ft. The upper limit of sweep var-
ies from ± 3/8 in. for wall panels and hollow-core units to ± 3/4
in. for joists usually used in composite construction.
13.2.4 Position of Strands
It is a common practice to use 5/8 in.-diameter holes in end
dividers (bulkheads or headers) for 3/8, 7/16, 1/2, and 0.6-in.-
diameter strands, because it is costly to switch end dividers
for different strand diameters. Therefore, better accuracy in
strand placement is achieved when using larger diameter
strands.
Generally, individual strands must be positioned within ±
1
/4 in. of design position and bundled strands within ± 1/2 in.
Hollow-core units have greater individual strand tolerances
as long as the center of gravity of the strand group is within ±
1
/4 in. and a minimum cover of 3/4 in. is maintained.
13.2.5 Camber and Differential Camber
Predicted camber is generally based on camber at release
of prestress; therefore, camber measurements on products
should be made as soon after stripping from the forms as pos-
sible. Differential camber refers to the final in-place condi-
tion of adjacent components.
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TOLERANCES FOR PRECAST AND PRESTRESSED CONCRETE CHAPTER 13

It is important that cambers are measured at the same Table 13.2.1  Typical tolerances for precast/prestressed
time of day, preferably in the early hours before the sun has concrete components
warmed the components. Cambers for all units used in the
Product tolerances Products
same assembly should be checked at the same age. If a signif-
icant deviation in camber from calculated values is observed,
the cause should be determined and the effect of the deviation Length
on the performance of the component should be evaluated. It ± 1/4 in. 18
± 3/8 in. 16, 17
should be understood that calculations predicting camber are ± 1/2 in. 6, 7, 8, 9, 13, 15
approximate and that the normal variations of the parameters ± 3/4 in. 3, 5
used can cause deviations of ± 20% over predicted camber. ± 1 in. 1, 2, 4, 11, 12, 14
Width
The final installed differential displacement between two  , 2, 3, 5, 6, 7, 8, 9, 12, 15,
1
± 1/4 in.
adjacent cambered components erected in the field may be 16, 18
the combined result of component differential cambers, vari- + /8 in.
3
14
+ 3/8 in., – 1/4 in. 4
ations in support elevations, variation in component depth, ± 3/8 in. 11, 13
and any adjustments made to the components during erec- ± 1/2 in. 17
tion. If differential cambers exceed recommended tolerances, Depth
+ 1/4 in., – 1/8 in. 10,18
additional effort is often required to erect the components in  , 2, 3, 5, 6, 7, 8, 9, 12, 13,
1
± 1/4 in.
a manner that is satisfactory for the intended use. 14, 15
+ 1/2 in., – 1/4 in. 4
For most flexural components, the tolerance for maximum ± 3/8 in. 11
camber variation from predicted camber is ± 3/4 in., and maxi- Flange thickness  
mum differential camber between adjacent units of the same

+ 1/4 in., –1/8 in.
± 1/4 in.
1, 2, 8, 10, 12, 15 13
design is 3/4 in. This may be increased for joists that are used 3, 4
Web thickness 
in composite construction. Pretopped precast concrete dou- ± 1/8 in. 1, 8, 10, 12, 15
ble-tees in parking structures should have a more stringent ± 1/4 in. 2,3
+ 3/8 in., –1/4 in. 4
tolerance for differential camber between adjacent double- ± 3/8 in. 5
tees so that a smooth riding surface is achieved. A 1/4 in. dif- Position of tendons
ferential is recommended in Reference 9. Recommendations ± 1/4 in.  , 2, 3, 4, 5, 6, 8, 9, 11, 12,
1
for camber and differential camber of hollow-core units are 14, 15, 18
± 1/4 in. thickness,
not listed because production variations between hollow-core
± 1 in. width 10
systems result in different tolerances for each type. Regional Camber, variation from design 
precast concrete manufactureres should be consulted for ± 1/4 in. per 10 ft, 1, 2, 12, 15
appropriate tolerances if differential hollow-core unit camber ± 3/4 in. maximum
± 1/8 in. per 10 ft, 4
tolerances are important for a particular project application. ± 1 in. maximum
± 3/4 in. maximum 3
13.2.6 Weld Plates ± /2 in. maximum
1
5, 15
Camber, differential
In general, it is easier to hold plates to closer tolerances at 1
/4 in. per 10 ft, 1, 2, 5
the bottom of a component (as cast or against the side form) 3
/4 in. maximum
than with plates cast in the top of the component. Bottom and ± 1/4 in. per 10 ft, 15
± 1/2 in. maximum
side plates can be fastened to the form and, hence, are less Bearing plates, position
susceptible to movement caused by vibration. This applies to ± 1/2 in. 1, 2, 3, 12, 15
position of weld plates as well as tipping and flushness. ± 5/8 in. 4
Bearing plates, tipping and
The tolerance on weld plates is less restrictive than for
flushness
bearing plates. The position tolerance is ± 1 in. for all prod- ± 1/8 in. 1, 2, 3, 4, 12, 13, 15
ucts. Tipping and flushness tolerance is ± 1/4 in.
13.2.7 Haunches of Columns and Wall Panels Key:
10 = architectural wall panel
The importance of corbel- or haunch-location tolerances 1 = double-tee
11 = pile
depends on the connection at the base of the component. 2 = single-tee
12 = joist
Because base connections usually allow some adjustability, 3 = building beam
13 = step unit (see section
it is more important to control dimensions from haunch to (rectangular and ledger)
13.2.2)
haunch in multilevel columns or walls than from haunch to 4 = I-beam
14 = sheet piling
the base of the component. 5 = box beam
15 = stadium riser unit
The haunch-to-haunch tolerance is ± 1/8 in. to ± 1/4 in. Bear- 6 = column
16 = prison cell module –
ing surface squareness tolerance is ± 1/8 in. per 18 in. with a 7 = hollow-core unit
single
maximum of ± 1/4 in., except for architectural precast con- 8 = ribbed wall panel
17 = prison cell module –
crete panels, which have a tolerance of ± 1/8 in., and columns, 9 = insulated wall panel
double
which have a maximum tolerance of ± 1/8 in. in the short 18 = prestressed concrete
direction and ± 3/8 in. in the long direction. panels for storage tanks

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 CHAPTER 13 TOLERANCES FOR PRECAST AND PRESTRESSED CONCRETE

Precast concrete panel

Warped plane

True plane

Distance to
farthest Corner
warping
adjacent corner
Distance to nearest
adjacent corner (controls
the magnitude of warping)

  Fig. 13.2.1 Definition of panel warping.

13

Maximum bowing Exposed Maximum

face bowing

Length of bow Length of bow

Plan Plan
(convex bowing) (concave bowing)

Bowing
Exposed
(plan)
face
(convex)

Exposed Bowing
face elevation Length of bow
(concave) (elevation)
Length of
bow Maximum
bowing

Precast concrete
panel
Length of bow
(plan)

Elevation Panel bowed in both

plan and elevation

Fig. 13.2.2 Definition of panel bowing.

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TOLERANCES FOR PRECAST AND PRESTRESSED CONCRETE CHAPTER 13

13.2.8 Warping and Bowing

Warping and bowing tolerances affect panel-edge matchup Exposed surface of precast concrete unit
during erection and the appearance of the erected compo- Variation in local
nents. These tolerances are especially critical with architec- smoothness
tural precast concrete panels. Warping is a deviation from 10 ft straight edge
plane in which the corners of the panel do not fall within the
same plane. Warping tolerances are given in terms of corner
deviations (Fig. 13.2.1). The allowable deviation from the
nearest adjacent corner is 1/16 in. per ft.
Bowing differs from warping in that two opposite edges
of a panel may fall in the same plane, but the portion of the
3 1 1
panel between the edges is out of plane (Fig. 13.2.2). Bowing 8 in. shim 2 in. roller in. roller 3 8 in. shim
4
tolerance is L /360, where L is the length of panel. Maximum (should not (must fit
tolerance on differential bowing between panels of the same fit between between
design is 1/2 in. surface and panel surface
straight edge and straight
The effects of differential temperature and moisture absorp-
at any point) edge over
tion between the inside and outside of a panel and the pre- entire surface
stress eccentricity should be considered in design of the panel
and its connections. Pre-erection storage conditions may also Fig. 13.2.3 Local smoothness variation.
affect warping and bowing (see Sections 5.8.5 and 8.4.2).  
Thin panels are more likely to bow than thick panels, and 13
the tolerances for thinner panels should be more liberal. Sim- they are produced by the same people, using the same type of
ilarly, panels made from concrete with a maximum aggre- formwork as plain, gray structural panels. Structural panels
gate size greater than 3/4 in., panels using two significantly with an architectural finish are made in PCI-Certified plants
different concretes, and veneered and insulated panels may that have a C-A certification. If more restrictive tolerances
require special consideration. In all cases, the regional pre- are required, they must be clearly indicated in the contract
caster should be consulted regarding overall economic and documents, and the subsequent increased costs should be
construction feasibility. considered.
13.2.9 Smoothness
13.3 Erection Tolerances
Local smoothness describes the condition where small
areas of the surface may be out-of-plane (Fig. 13.2.3). The 13.3.1 General
tolerance for this type of variation is 1/4 in. per 10 ft for
all products. The tolerance is usually checked with a 10 ft Erection tolerances are those to which the primary control
straight edge or the equivalent, as explained in Fig. 13.2.3. surfaces of the component should be set. The final location of
other features and surfaces will be the result of the combina-
13.2.10 A
 rchitectural Panels versus Structural tion of the the erection tolerances given in this section and
Products the product tolerances given in Section 13.2. Table 13.3.1
When discussing tolerances, an architectural panel refers lists erection tolerances for interface design of precast and
to a class of specified tolerances, not necessarily to the use cast-in-place concrete components. Table 13.3.2 lists recom-
of the component in the final structure. Architectural pan- mended clearances.
els usually require more restrictive tolerances than structural Because erection depends on the equipment used and
components for aesthetic reasons. These types of panels are site, there may be good reasons to vary some of the recom-
produced in PCI-Certified plants that have an A1 certifica- mended tolerances to account for unique project conditions.
tion. Structural products such as load-bearing spandrel pan- In general, the more restrictive the erection tolerances are,
els, insulated sandwich panels, double-tees, hollow-core the higher the cost of erection will be. To minimize erection
units, and solid slabs are often used for exterior facades but problems, the dimensions of the in-place structure should be
are not considered architectural panels. Because of the pro- checked prior to starting erection. After erection, and before
duction method used, structural products with an applied other trades interface with the precast concrete components,
architectural finish have the same tolerance requirements it should be verified that the precast concrete components are
that they would have if they were made without an aesthetic erected within tolerances.6
finish. Many structural products are larger than typical archi-
tectural panels and require the larger tolerances given in
MNL-116-99. Also, structural panels with architectural fin-
ishes often carry substantial loads, as in the case of a spandrel
panel of a parking garage. These type of panels need to have
the larger tolerances specified for structural panels because

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 CHAPTER 13 TOLERANCES FOR PRECAST AND PRESTRESSED CONCRETE

Table 13.3.1  Erection tolerances for interface design of Table 13.3.2  Recommended clearances
precast and cast-in-place concrete components
Recommended minimum
Item
clearance
Recommended
Item Precast concrete compo-
tolerances nent to precast concrete /2 in. (1 in. preferred)
1

component
Variation in plan location (any column Precast concrete com-
or beam, any location)....................... ± 1/2 in. for columns, ponent to cast-in-place 1 in. (2 in. preferred)
concrete
± 1 in. for beams
Precast concrete compo-
Variation in plan parallel to 1 in. (2 in. preferred)
nent to steel
specified building lines....................... + 1/40 in. per ft for any
beam less than 20 ft long Precast concrete column 11/2 in. (3 in. preferred for
or adjacent to columns covers tall buildings)
spaced less than 20 ft
apart
13.3.2 Recommended Erection Tolerances
1
/2 in. maximum for adja-
cent columns spaced 20 ft Figures 13.3.2 through 13.3.9 show erection tolerances for
or more apart the following four mixed building systems:
• precast concrete component to precast concrete
Difference in relative position of
component
  adjacent columns from specified
13 relative position (at any check • precast concrete component to cast-in-place
level).................................................. + 1/2 in. concrete
• precast concrete component to masonry
Variation from plumb.......................... + 1/4 in. for any 10 ft of
height
• precast concrete component to structural steel
construction
1 in. maximum for the See Reference 4 for recommended erection tolerances for
entire height additional precast concrete components.
Variation in elevation of bearing
The tolerances outlined in this section should be the speci-
surfaces from specified elevation fied tolerances for erection of precast concrete components.
(any column or beam, any location).. Maximum low = 1/2 in. If tolerances are desired that are different from those pub-
Maximum high = 1/4 in. lished in PCI documents, this should be made very clear to
bidders in the bid documents.
Variation of top of spandrel from
specified elevation 13.3.3 Mixed Building Systems
(any location)..................................... + 1/2 in.
Mixed building systems combine precast and prestressed
Variation in elevation of bearing concrete with other materials, usually cast-in-place concrete,
surfaces from lines parallel to
specified grade lines.......................... + 1/40 in. per ft for any masonry, or steel. Typically each industry has its own rec-
beam less than 20 ft long ommended erection tolerances that apply when its products
or for adjacent columns are used exclusively. The compatibility of those tolerances
spaced less than 20 ft
apart

1
/2 in. maximum for any
beam 20 ft or more in Precast concrete component
length or for adjacent col-
umns spaced 20 ft or more
apart
Bearing pad
Variation from specified bearing
length on support............................... ± 3/4 in. Set back
distance
Variation from specified bearing
width on support................................ ± 1/2 in. Bearing length
Jog in alignment of matching Length over support
edges................................................. 1/2 in. maximum

Support

Fig. 13.3.1 Relationship between bearing length and length

over support.

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TOLERANCES FOR PRECAST AND PRESTRESSED CONCRETE CHAPTER 13

with the precast concrete tolerances should be checked and

adjusted when necessary.
Example 13.4.2 presents a problem that can occur when
erection tolerances are chosen for each system without con-
sidering the project as a whole.
13.3.4 Connections and Bearing
The details of connections must be considered when speci-
fying erection tolerances. Space must be provided to perform
the tasks necessary to complete the connection under the
most adverse combination of tolerances.
Bearing length is measured in the direction of the span, and
bearing width is measured perpendicular to the span. Bearing
length is often not the same as the length of the component’s
end projecting over the support (Fig. 13.3.1). When they dif-
fer, it should be noted on the erection drawings.
The engineer may wish to specify a minimum bearing (size,
length, and width) for various precast concrete products. For
additional information, see Reference 6.
 
13

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 CHAPTER 13 TOLERANCES FOR PRECAST AND PRESTRESSED CONCRETE

Fig 13.3.2  Beam erection tolerances

Building grid
datum
a

e
f

Vertical primary
control surface
  (N/A at inverted
13 tee beam)

Plan

c c
•
d

Horizontal
b
primary
control
b surface
(at support)

Ledge both sides at Precast concrete beam

inverted tee beam
a1
Support component

Centerline of steel support

Elevation

Precast concrete component to precast concrete component, cast-in-place concrete, masonry, or structural steel

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Fig. 13.3.2  Beam erection tolerances (cont.)

The primary control surfaces for beam erection tolerances are usually as shown, although this needs
to be confirmed on a job-by-job basis.

a = Plan location from building grid datum................................................................................. ± 1 in.

a1 = Plan location from centerline of steela................................................................................. ± 1 in.

b = Bearing elevationb from nominal elevation at support:

Maximum low...................................................................................................................... 1/2 in.
Maximum high..................................................................................................................... 1/4 in.

c = Maximum plumb variation over height of component:

Per 12 in. height.................................................................................................................. 1/8 in.
Maximum at rectangular or L-beam.................................................................................... 1/2 in.
Maximum at inverted-tee beam.......................................................................................... 3/4 in.

d = Maximum jog in alignment of matching edges:  

Architectural exposed edges............................................................................................... 1/4 in. 13
Visually non-critical edges.................................................................................................. 1/2 in.

e = Joint width:
Architectural exposed joints............................................................................................. ± 1/4 in.
Hidden joints.................................................................................................................... ± 3/4 in.
Exposed structural joint not visually critical..................................................................... ± 1/2 in.

f = Bearing lengthc (span direction).......................................................................................... ± 3/4 in.

g = Bearing widthc..................................................................................................................... ± 1/2 in.

Note: When bearing pads are used at unarmored edges, they should be set back a minimum of 1/2 in.
from the face of the support or at least the chamfered dimension at chamfered edges.

a. For precast concrete components on a steel frame, this tolerance takes precedence over tolerance
on dimension a.

b. Or component top elevation where component is part of a frame without bearing ledges.

c. This is a setting tolerance and should not be confused with structural performance requirements
set by the architect/engineer. The nominal bearing dimensions and the allowable variations
in the bearing length and width should be specified by the engineer and shown on the erection
drawings.

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 CHAPTER 13 TOLERANCES FOR PRECAST AND PRESTRESSED CONCRETE

Fig. 13.3.3  Floor and roof component erection tolerances

Building grid Building grid

datum datum

a a

a a g
g
d d

 
13 c c
Hollow-core plan Double-tee plan

Centerline of Primary control surface Centerline of

steel support for carpet direct steel support
a1 a1
e
e

Hollow-core Double-tee

Support h Support
component Primary control surface component Primary control
b for topped deck with b surface for
To allow for exposed underside To allow for pretopped tee
-3 4 in. tolerance Bearing pad by design -3 4 in. tolerance Bearing pad by design
3 in. 3 in.
4 4
f Holdback as required f Holdback as required
Building elevation datum
Hollow-core elevation Double-tee elevation

Precast concrete component to precast, cast-in-place concrete, masonry or structural steel support

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Fig. 13.3.3  Floor and roof component erection tolerances (cont.)

The primary control surfaces for floor and roof component erection tolerances are usually as shown.
Tyipcally, there is no designated vertical, primary control surface, and in some scenarios, there are
no primary control surfaces at all. This needs to be determined on a job-by-job basis.

a = Plan location from building grid datum................................................................................. ± 1 in.

a1 = Plan location from centerline of steel supporta.................................................................... ± 1 in.

b = Top elevation from building elevation datum at component ends:

Covered with topping....................................................................................................... ± 3/4 in.
Pretopped tee/carpet direct hollow-core unit................................................................... ± 1/4 in.
Untopped roof.................................................................................................................. ± 3/4 in.

c = Maximum jog in alignment of matching edges

(both topped and untopped construction)................................................................................1 in.

d = Joint width:
0 ft to 40 ft component..................................................................................................... ± 1/2 in.
 
41 ft to 60 ft component................................................................................................... ± 3/4 in. 13
61 ft + component............................................................................................................. ± 1 in.

e = Differential top elevation as erected (for units of same design and length):
Field topped........................................................................................................................ 3/4 in.
Pretopped tees at driving lanes.......................................................................................... 1/4 in.
Carpet direct hollow-core slabs.......................................................................................... 1/4 in.
Untopped roof b................................................................................................................... 3/4 in.

f = Bearing lengthc (span direction).......................................................................................... ± 3/4 in.

g = Bearing widthc (not applicable for hollow-core slabs)......................................................... ± 1/2 in.

h = Differential bottom elevation of exposed hollow-core slabsd................................................. 1/4 in.

Note: When bearing pads are used at unarmored edges they should be set back a minimum of 1/2 in.
from the face of the support or from at least the chamfered dimension at chamfered edges.

a.  or precast concrete erected on a steel frame building, this tolerance takes precedence over toler-
F
ance on dimension a.

b. It may be necessary to feather the edges to ± 1/4 in. to properly apply some roof membranes.

c.  his is a setting tolerance and should not be confused with structural performance requirements
T
set by the architect/engineer. The nominal bearing dimensions and the allowable variations
in the bearing length and width should be specified by the engineer and shown on the erection
drawings.

d. Untopped installations will require a larger tolerance.

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 CHAPTER 13 TOLERANCES FOR PRECAST AND PRESTRESSED CONCRETE

Fig. 13.3.4  Column erection tolerances

d d
Building grid •
datum
a a
•

Plan
 
13

Vertical primary
control surface

Splice
Horizontal primary control
surface (at first corbel) f

e e
•
100'-0"

10'-0"

Building elevation
datum
a

Building grid
Building elevation datum
datum

Elevation Elevation

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Fig 13.3.4  Column erection tolerances (cont.)

The primary control surfaces are usually as shown, although this needs to be confirmed on a job-by-
job basis.

a = Plan location from building grid datum:

Structural applications...................................................................................................... ± 1/2 in.
Architectural applications................................................................................................. ± 3/8 in.

b = Top elevation from nominal top elevation:

Maximum low..................................................................................................................... 1/2 in.
Maximum high.................................................................................................................... 1/4 in.

c = Bearing haunch elevation from nominal elevation:

Maximum low..................................................................................................................... 1/2 in.
Maximum high.................................................................................................................... 1/4 in.

d = Maximum plumb variation over height of component

(component in structure of maximum height of 100 ft):......................................................... 1 in.  
13
e = Plumb in any 10 ft of element height.................................................................................... 1/4 in.

f = Maximum jog in alignment of matching edges:

Architectural exposed edges.............................................................................................. 1/4 in.
Visually non-critical edges................................................................................................. 1/2 in.

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Fig. 13.3.5  Structural wall panel erection tolerances

A
g f
d d Horizontal
h
a Building grid primary
datum Vertical primary control
control surface surface
Precast
concrete
panel
e e b h 10
i
c

10'-0"
Cast-in-place

10'-0"
foundation of
a precast con-
crete support Building
elevation
Cast-in-place or datum Nominal joint width
precast concrete

Plan Section A Elevation

 
13

Precast concrete component to precast concrete or cast-in-place concrete or masonry

f
a d d Horizontal g h
Building grid primary
datum Vertical primary control
control surface surface
Support
component e e
b h10
i a c
10'-0"
10'-0"

g
Steel Building
structure grid
Centerline of datum
a1 steel structure
Nominal joint width
Plan Section Elevation

Precast concrete components to structural steel

Bowing section – panels

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Fig. 13.3.5  Structural wall panel erection tolerances (cont.)

The primary control surfaces are usually as shown, although this needs to be confirmed on a job-by-
job basis.

a = Plan location from building grid datuma.............................................................................. ± 1/2 in.

a1 = Plan location from centerline of steel support..................................................................... ± 1/2 in.

b = Top elevation from nominal top elevation:

Exposed individual panel................................................................................................. ± 1
/2 in.
Non-exposed individual panel.......................................................................................... ± 3
/4 in.
Exposed relative to adjacent panel.................................................................................. ± 1
/2 in.
Non-exposed relative to adjacent panel.......................................................................... ± 3
/4 in.

c = Support elevation from nominal elevation:

Maximum low...................................................................................................................... 1/2 in.
Maximum high..................................................................................................................... 1/4 in.
 
d = Maximum plumb variation over height of 13
structure or over 100 ft, which ever is lessa........................................................................... 1 in.

e = Plumb in any 10 ft of element height.................................................................................... 1/4 in.

f = Maximum jog in alignment of matching edges...................................................................... 1/2 in.

g = Joint width (governs over joint taper).................................................................................. ± 3/8 in.

h = Joint taper over height of panel............................................................................................. 1/2 in.

h10 = Joint taper over 10 ft height.................................................................................................. 3/8 in.

i = Maximum jog in alignment of matching faces:

Exposed to view................................................................................................................. 3/8 in.
Not exposed to view.......................................................................................................... 3/4 in.

j = Differential bowing as erected

between adjacent components of the same designb............................................................ 1/2 in.

a. For precast concrete buildings in excess of 100 ft tall, tolerances a and d can increase at the rate of
1
/8 in. per story to a maximum of 2 in.

b. Refer to Section 13.2.8 for description of bowing tolerance.

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Fig. 13.3.6  Architectural walls/spandrel erection tolerances

Building grid h
datum dd Horizontal primary
a • control surface
f
Vertical primary
i control surface

e e
• h10
a
b
g

10'-0"
10'-0"

Centerline of c
steel support
Building
a1 Support elevation
component datum
 
13 Plan Section Elevation
Walls Walls Walls

Building grid
datum dd Horizontal primary
a • control surface
h or h 10
Vertical primary
i control surface

e e
•
k
b
f
a
10'-0"

g
Centerline of
steel support c

Building
elevation
a1 Support datum
component
Plan Side Elevation
Spandrels Spandrels Spandrels

Bowing plan
Spandrels

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Fig. 13.3.6  Architectural walls/spandrel erection tolerances (cont.)

The primary control surfaces are usually as shown, although this needs to be confirmed on a job-by-
job basis.

a = Plan location from building grid datuma.............................................................................. ± 1/2 in.

a1 = Plan location from centerline of steel supportb................................................................... ± 1/2 in.

b = Top elevation from nominal top elevation:

Exposed individual panel.................................................................................................. ± 1/4 in.
Non-exposed individual panel........................................................................................... ± 1/2 in.

c = Support elevation from nominal elevation:

Maximum low....................................................................................................................... 1/2 in.
Maximum high...................................................................................................................... 1/4 in.

d = Maximum plumb variation over height of structure

or 100 ft, whichever is lessa................................................................................................... 1 in.  
13
e = Plumb in any 10 ft of element height.................................................................................... 1/4 in.

f = Maximum jog in alignment of matching edges:

Exposed relative to adjacent panel..................................................................................... 1/4 in.
Non-exposed relative to adjacent panel............................................................................. 1/2 in.

g = Joint width (governs over joint taper).................................................................................. ± 1/4 in.

h = Joint taper maximum............................................................................................................. 3/8 in.

h10 = Joint taper over 10 ft length.................................................................................................. 1/4 in.

i = Maximum jog in alignment of matching faces....................................................................... 1/4 in.

j = Differential bowing as erected between adjacent components

of the same design:
Exposed relative to adjacent panel..................................................................................... 1/4 in.
Non-exposed relative to adjacent panel............................................................................. 1/2 in.

k = Opening height between spandrels..................................................................................... ± 1/4 in.

a. For precast concrete buildings in excess of 100 ft tall, tolerances a and d can increase at the rate
of 1/8 in. per story to a maximum of 2 in.

b. For precast concrete components erected on a steel frame, this tolerance takes precedence over toler-
ance on dimension a.

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 CHAPTER 13 TOLERANCES FOR PRECAST AND PRESTRESSED CONCRETE

Fig. 13.3.7  Single, double, and triple riser erection tolerances

Theoretical
centerline of support
b
a
Building grid
or datum (typical)
f e

h e
k
Vertical primary
control surface
Plan

 
13
To allow for
-1 in. tolerance
Holdback as required
1 in.

Shims per design

Horizontal primary
control surface

d
c
Elevation
Building grid
or datum (typical)
Horizontal primary
e
control surface Vertical primary
control surface
g or j

Cross section

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Fig. 13.3.7  Single, double, and triple riser erection tolerances (cont.)

The primary control surfaces for single, double, and triple riser erection tolerances are usually as
shown, although this is something that needs to be confirmed with the contractor on a job-by-job
basis. Local building codes may require more restrictive riser-height tolerances, which could also
affect product tolerance.

a = Plan location from building grid line datum.......................................................................... ± 1 in.

b = Plan location from theoretical centerline of support structure.............................................. ± 1 in.

c = Top elevation from building elevation datum at member’s end (datum may be adjusted to
accommodate existing field conditions.)............................................................................. ± 1/2 in.

d = Maximum jog in alignment of matching edges

at the horizontal primary control surface................................................................................ 1/4 in.

e = Maximum jog in alignment of matching edges

at the vertical primary control surface.................................................................................... 1/2 in.  
13
f = Bearing in span direction........................................................................................................–1 in.

g = Joint width (horizontal) at end of piece (joint

width needs to be 1/4 in. minimum)...................................................................................... ± 1/2 in.

h = Joint width (joint width needs to be 1/4 in. minimum in either case)
90 deg angle.................................................................................................................... ± 1/2 in.
Joint width at skewed ends . ........................................................................................... ± 5/8 in.

j = Differential camber (at midspan as erected) between adjacent components of the same
design................................................................................ ± 3/16 in. per 10 ft of component length

k = Differential sweep (at midspan as erected) between adjacent components of the same
design................................................................................ ± 3/16 in. per 10 ft of component length

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Fig. 13.3.8  Room module erection tolerances

Building grid
or datum (typical)
f
a

 
13
a

Plan

Vertical primary control

surface (front) d d
•

c
e

Horizontal primary
control surface
b (door head)

Elevation

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Fig. 13.3.8  Room module erection tolerances (cont.)

The tolerances listed below (a–g) are used at the primary control surfaces only, and only those tol-
erances that are applicable to that surface are used. Normally, the primary control surfaces are the
front face of the room module as the vertical primary control surface, and either the head of the door,
top of room module, or the bottom of balcony as the horizontal primary control surface.
Note: On jobs where pretopped balconies are cast as part of the room module, the horizontal primary
control surface may be the top surface of the balcony.

a = Plan location from building grid line datum......................................................................... ± 1/2 in.

b = Vertical control (at primary control surface)

from a horizontal datum...................................................................................................... ± 3/8 in.

c = Actual grout joint.................................................................................................... 1/2 in. minimum

d = Plumb at element height........................................................................................................ 1/4 in.

e = Maximum jog in alignment of matching edges....................................................................... 1/4 in.  

13
f = Vertical joint width............................................................................................................... ± 3/8 in.

g = Joint taper.................................................................................................................Not applicable

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Fig. 13.3.9  Stair unit erection tolerance

c
e
a

 
13 Building grid Plan
or datum (typical)

Primary control surface

Line of topping
pan (if applicable)

Intermediate landing
b
g

Elevation

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Fig. 13.3.9  Stair unit erection tolerance (cont.)

The primary control surface for stair units is the top of landing at floor levels. The tolerances listed
here (a–g) are the same whether landings are monolithic or separate pieces. Local building codes
may require more restrictive riser-height tolerance, which could also affect the product tolerance.

a = Plan location from building grid line datum......................................................................... ± 1/2 in.

b = Differential elevation as erecteda........................................................................................ ± 3/8 in.

c = Joint width........................................................................................................................... ± 3/4 in.

d = Maximum jog in alignment of matching edges.........................................................................1 in.

e = Maximum jog in alignment of stair tread nosings

(tolerance overrides d if needed)........................................................................................... 1/2 in.

f = Maximum jog in alignment of matching edges

at the primary control surfacea............................................................................................... 3/8 in.  
13
g = Bearing (in span direction).................................................................................................. ± 3/4 in.

a. At stair units that have pretopped precast concrete landings, the maximum jog between stair
units, as well as from stair unit to finish floor, cannot exceed 1/4 in. However, units that have land-
ings that are topped have more leeway. This needs to be discussed and agreed on with the gen-
eral contractor. See Section 13.2.2.

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 CHAPTER 13 TOLERANCES FOR PRECAST AND PRESTRESSED CONCRETE

13.4 Clearances ponents in the structure and how connections will be made.
Adjust the clearance as required.
13.4.1 General
Step 5: Review the clearance to see whether increasing
Clearance is the space between adjacent construction ele- its dimensions will allow easier, more economical erection
ments and provides a buffer area where erection and produc- without adversely affecting aesthetics. Adjust the clearance
tion tolerance deviations can be absorbed. The following as required.
items should be addressed when determining the appropriate Step 6: Review structural considerations such as types of
clearance to provide in the design: connections involved, sizes required, bearing area require-
• product tolerance ments, and other structural issues.
• type of component Step 7: Check design to ensure adequacy in the event that
• size of component minimum component size should occur. Adjust clearance as
• type of abutting construction required for minimum bearing and other structural consid-
• location of component erations.
• component movement
• function of component Step 8: Select final clearance that will satisfy all of the
• erection tolerance conditions considered.
• space required for fireproofing of steel 13.4.4 Clearance Examples
• thickness of plates, bolt heads, and other projecting
elements The following examples are given to show the thought pro-
 
13 Of these factors, product tolerances and component move-
cess, and may not be the only solutions for the situations that
are described (Fig. 13.4.1 and 13.4.2).
ment are the most significant. As shown in the following
examples, it may not always be practical to account for all
possible factors in the clearance provided. Table 13.3.2 pro-
vides recommended minimum clearances for various mixed
building systems.
13.4.2 Joint Clearance
Joints between architectural panels must accommodate
variations in the panel dimensions and erection tolerances
for the panels. They must also provide a good visual line
and be sufficiently wide to allow for proper joint-sealant
installation. Generally, the larger the panels are, the wider
the joints should be. For most situations, architectural panel
joints should be designed as being not less than 3/4 in. wide.
Tolerances in overall building width and length are normally
accommodated in panel joints.
13.4.3 Procedure for Determining Clearance
The following is a systematic approach for making a trial
selection of a clearance value and then verifying that selec-
tion to ensure that it will allow practical erection to occur:
Step 1: Determine the maximum size of the components
involved (basic or nominal dimension and additive toler-
ances). This should include not only the precast/prestressed
concrete components, but also other materials.
Step 2: To the maximum component size, add the mini-
mum space required for component movement resulting
from deflection and thermal variations.
Step 3: Check if the resulting clearance allows the com-
ponent to be erected within the erection and interfacing
tolerances, such as plumbness, face alignment, and the like.
Adjust the clearance as required to meet all the needs.
Step 4: Check if the component can physically be erected
with this clearance. Consider the size and location of com-

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TOLERANCES FOR PRECAST AND PRESTRESSED CONCRETE CHAPTER 13

60'-0" (+
–1 in.)
Double-tee roof component
(long term shortening, – 14 in.)

Detail

Wall thickness tolerance

25'-0" (+14 in., –18 in.) Plumb tolerance
(14 in. per 10 ft)

Ribbed wall panels

 
+ 1
– 2 in. plan variance + 1
– 2 in. plan variance 13
Elevation

3
4 in. clearance

Precast
concrete
ribbed
Precast, prestressed
wall panel
concrete double-tee
roof component

6 in.

Detail

Fig. 13.4.1 Clearance example.

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 CHAPTER 13 TOLERANCES FOR PRECAST AND PRESTRESSED CONCRETE

EXAMPLE 13.4.1
Clearance Determination – Single-Story Industrial Building

Given:
A 60-ft-long double-tee roof component is bearing on ribbed wall panels that are 25 ft high with a haunch depth
of 6 in. beyond the face of the panel. Long-term roof movement is expected to be 1/4 in.
Tolerance items to consider (refer to Fig. 13.4.1):
• Double-tee length tolerance ±1 in.
• Maximum plan variance ± 1/2 in.
• Variation from plumb 1/2 in. per 10 ft

Problem:
Find the minimum acceptable clearance.

_________________________________________________________________________________________
 
13 Solution:
Step 1: Determine maximum component sizes.
(Refer to Table 13.2.1)
Maximum double-tee length = +1 in.
Wall thickness = +1/4 in.
Initial clearance chosen = 3/4 in. per end

Step 2: Component movement.

 Long-term shrinkage and creep will increase the clearance, so this movement can be neglected in
the initial clearance determination, although it must be considered structurally.
Required clearance adjustment
as a result of component movement 0
Clearance chosen (from step 1) 3
/4 in.

Step 3: Other erection tolerances.

If the ribbed wall panel is set inward toward the building interior 1/2 in. and erected plumb, this would
suggest the clearance should be increased by 1/2 in. However, if the panel is erected out of plumb
outward 1/2 in., no clearance adjustment is needed.
Clearance adjustment required
for erection tolerances =0
Clearance chosen (from step 1) = 3/4 in.

Step 4: Erection considerations.

If all components are fabricated perfectly, then the joint clearance is 3/4 in. at either end (13/4 in. total).
This is ample space for erection. If all components are at maximum size variance, maximum inward
plan variance, and maximum inward variance from plumb, then the total clearance is zero. This is
undesirable, as it would require some rework during erection. A judgment should be made as to the
likelihood of maximum product and erection tolerances all occurring in one location. If the likelihood
is low, the 3/4 in. clearance does not need adjustment, but, if the likelihood is high, the engineer might
increase the clearance. In this instance, the likelihood has been judged low; therefore, no adjustment
has been made.
Clearance chosen (from step 1) = 3/4 in.

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EXAMPLE 13.4.1
Clearance Determination – Single-Story Industrial Building (cont.)

Step 5: Economy.

In single-story construction, increasing the clearance beyond 3/4 in. is not likely to speed up erection
as long as product tolerances remain within allowables. Adjustment is not required for economic
considerations.

Step 6: Review structural considerations.

Allowing a setback from the edge of the corbel, assumed in this instance to have been set by the
engineer at 1/2 in. plus the clearance, the bearing is 4 in. There should be space to allow component
movement. The engineer judges this to be acceptable from a structural and architectural point of view
and no adjustment is required for structural considerations.

Step 7: Check for minimum component sizes.

 
(Refer to Table 13.2.1) 13
Tee length –1 in. (1/2 in. each end)
Wall thickness –1/8 in.
Bearing haunch No change
Clearance chosen 3
/4 in.
Minimum bearing with setback +4 in.
(OK in this instance)
Wall plumbness would also be considered in an actual application.

Step 8: Solution.

Minimum clearance used 3

/4 in. per end

(Satisfies all conditions considered.)

Note: For simplicity in this example, end rotation, flange skew, and global skew tolerances have not been

considered. In an actual situation, these issues should also be considered.

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 CHAPTER 13 TOLERANCES FOR PRECAST AND PRESTRESSED CONCRETE

Maximum displacement Theoretical centerline of column

from theoretical column
centerline: toward 2 in.
building line
Away from building 3 in.
line
36 stories

Possible position of 1
4 in.
precast concrete facade

Actual position of column

1 in.
 
13
20 stories

2 in.

Theoretical plane of
precast concrete facade
building line Steel framing
constructed as per AISC
Code of Standard Practice
Detail

2 3 4 in.
(clearance)

Precast
concrete facade
Detail

Steel framing

Fig. 13.4.2 Clearance example – high-rise steel-frame structure.

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TOLERANCES FOR PRECAST AND PRESTRESSED CONCRETE CHAPTER 13

EXAMPLE 13.4.2
Clearance Determination – High-Rise Steel-Frame Structure

Given:
A 36-story, steel-frame structure, with precast concrete cladding, steel tolerances per AISC 303-05 and neg-
ligible component movement. In this example, precast concrete tolerance for variation in plan is ± 1/4 in. Refer
to Fig. 13.4.2.

Problem:
Determine whether the panels can be erected plumb and determine the minimum acceptable clearance at the
36th story.

_________________________________________________________________________________________

Solution:
Step 1: Product tolerances.
(refer to Table 13.2.1)  
Precast concrete cladding thickness = + 1/4 in., – 1/8 in. 13
Steel width = + 1/4 in., – 3/16 in.
Steel sweep (varies) = ± 1/4 in. (assumption)
Initial clearance chosen = 3
/4 in.

Step 2: Component movement.

For simplification, assume this can be neglected in this example.

Step 3: Other erection tolerances.

Steel variance in plan, maximum = 2 in.
Initial clearance = 3/4 in.
Clearance chosen = 23/4 in.

Step 4: Erection considerations.

No adjustment required for erection considerations.

Step 5: Economy.
Clearance chosen = 23/4 in.
Increasing clearance will not increase economy.
No adjustment for economic considerations.

Step 6: Structural considerations.

Clearance chosen = 23/4 in.
Expensive connection, but possible. No adjustment.

Step 7: Check minimum component sizes at 36th story (refer to Table 13.2.1).
Initial clearance = 23/4 in.
Precast concrete thickness = 1/8 in.
Steel width = 3/16 in.
Steel sweep = 1/4 in.
Steel variance in plan minimum = 3 in.
Clearance calculated = 65/16 in.

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 CHAPTER 13 TOLERANCES FOR PRECAST AND PRESTRESSED CONCRETE

EXAMPLE 13.4.2
Clearance Determination – High-Rise Steel-Frame Structure (cont.)

Step 8: Solution.
A clearance of over 6 in. would require an extremely expensive connection for the precast concrete
panel, and would produce high torsional stresses in the steel supporting beams. The 6 in. clearance is not
practical, although the 23/4 in. minimum initial clearance is still needed. Either the precast concrete panels
should be allowed to follow the steel frame or the tolerances for the exterior columns need to be made more
stringent, such as the AISC requirements for elevator columns. The most economical choice will likely be for
the precast concrete panels to follow the steel frame.
Minimum clearance used: = 23/4 in. Use 3 in.
Allow panels to follow the steel frame.

13.5 Interfacing Tolerances as conflict with prestressing strands.

  13.5.1 General
13
In interfacing with other materials, the tolerances may be
very system-dependent. For example, different brands of
windows may have different tolerance requirements. If prod-
uct substitutions are made after the initial design is complete,
the interface details must be reviewed for the new system.
Following is a partial checklist for consideration in determin-
ing interfacing requirements:
• structural requirements
• volume change
• exposure and corrosion protection
• waterproofing
• drainage requirements
• architectural requirements
• dimensional considerations
• vibration considerations
• fire-rating requirements
• acoustical considerations
• economics
• manufacturing/erection considerations
13.5.2 Interface Design Approach
The following approach is one method of organizing the
task of designing the interface between two systems.
Step 1: Review the interface between the two systems,
show shape and location, and determine contractual respon-
sibilities. For example, the precast concrete panel is fur-
nished by the precast concrete manufacturer, the window is
furnished and installed by the window manufacturer, and
the sealant between the window and the precast concrete is
furnished and installed by the general contractor.
Step 2: Review the functional requirements of each inter-
facing system. For example, the building drain line must
have a flow line slope that allows for adequate drainage.
This will place limits on where the line must penetrate pre-
cast concrete units. Note whether this creates problems such
Step 3: Review the tolerances of each interfacing system.
For example, determine the external tolerances on the door
jamb from the manufacturer’s specifications. Determine
the tolerance on a large-panel door blockout from the pre-
cast concrete product tolerances. For the door installation,
determine the floor surface tolerance in the area of the door
swing path.
Step 4: Review the operational clearances required. For
example, determine the magnitude of operational clearances
that are needed to align the door so it functions properly,
and then choose dimensions that include necessary clear-
ances.
Step 5: Review the compatibility of the interface toler-
ances. Starting with the least precise system, check the
tolerance requirements and compare them with the mini-
mum and maximum dimensions of the interfacing system.
If interferences result, alter the nominal dimension of the
appropriate system. For example, it is usually more eco-
nomical to make a somewhat larger or smaller opening than
to specify a non-standard window size.
Step 6: Review assembly and installation procedures for
the interfacing systems to ensure compatibility. Show the
preferred adjustments to accommodate the tolerances of the
systems. Consider such things as minimum bearing areas,
minimum and maximum joint gaps, and other dimensions
that will vary as a result of interface tolerances. Consider
economic trade-offs such as in-plant work versus field
work, and minor fit-up rework versus more restrictive toler-
ances.
Step 7: Review the final project specifications as they
relate to interfacing. Be aware of the interface consequenc-
es of subsystem substitutions that might be made during the
final bidding and procurement.

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TOLERANCES FOR PRECAST AND PRESTRESSED CONCRETE
13.5.3 Characteristics of the Interface
The following list of questions will help to define the nature
of the interface:
1. What specifically is to be interfaced?
2. How does the interface function?
3. Is there provision for adjustment upon installation?
4. How much adjustment can occur without rework?
5. What are the consequences of an interface tolerance
mismatch?
• Rework requirements (labor and material)
• Rejection limits
6. What are the high material-cost considerations of the
interface?
7. What are the high labor-cost considerations of the
interface?
8. What are the normal tolerances associated with the
systems to be interfaced?
9. Are the system interface tolerances simple planar
tolerances or are they more complex and three-
dimensional?
10. Do all of the different products of this type have the
same interface tolerance requirements?
11. Does the designer of the precast concrete system
have control over all of the aspects of the interfaces
involved? If not, what actions need to be taken to
accommodate this?
Listed below are common characteristics to be considered
for most systems of the type listed:
1. Windows and doors
• No gravity load transfer through window
element
• Compatible with air and moisture sealant system
• Open/close characteristics (swing or slide)
• Compatibility with door locking mechanisms
2. Mechanical equipment
• Duct clearances for complex prefabricated
ductwork
• Large-diameter prefabricated-pipe clearance
requirements
• Deflections from forces associated with large-
diameter piping and valves
• Expansion/contraction allowances for hot and
cold piping
• Vibration isolation/transfer considerations
• Acoustical shielding considerations
• Hazardous gas/fluid containment requirements
3. Electrical equipment
• Multiple mating conduit runs
• Prefabricated cable trays
• Embedded conduits and outlet boxes
• Corrosion related to DC (direct current) power
• Special insert placement requirements for isolation
• Location requirements for embedded ground-
ing cables
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CHAPTER 13
• Shielding clearance requirements for special
clean electrical lines
4. Elevators and escalators
• Elevator guide location requirements
• Electrical conduit location requirements
• Elevator door mechanism clearances
• Special insert placement requirements
• Door opening size
5. Architectural cladding
• Joint tolerance for sealant system
• Flashing and reglet fit-up (Lining up cast-in
reglets from panel to panel is very difficult and
often costly. Surface-mounted flashing should
be considered.)
• Expansion and contraction provisions for dis-
similar materials
• Effects of rotation, deflection, and differential
thermal gradients
 
6. Structural steel and miscellaneous steel 13
• Details to prevent rust staining of concrete
• Details to minimize potential for corrosion at
field connections between steel and precast
concrete
• Coordination of structural steel expansion/con-
traction provisions with those of the precast
concrete system
• Special provisions for weld plates or other
attachment features for steel structures
• Consideration of thermal insulation and fire-
proofing requirements
7. Masonry
• Coordination of masonry expansion/contrac-
tion provisions with those of the precast con-
crete system
• Detailing to ensure desired contact bearing
between masonry and precast concrete units
• Detailing to ensure desired transfer of load
between masonry shear wall and precast con-
crete frame
• Requirements for dovetail anchors—field
installation always preferred
8. Roofing
• Roof camber, both upon erection and over the
long-term, as it relates to roof drain placement
• Fit-up of prefabricated flashing
• Dimensional effects of added material during
reroofing
• Coordination of structural control joint loca-
tions with roofing system expansion/contrac-
tion provisions
• Location of embedded heating, ventilating, and
air-conditioning unit supports
• Deflections due to live load and added equip-
ment dead loads
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 CHAPTER 13 TOLERANCES FOR PRECAST AND PRESTRESSED CONCRETE

9. Waterproofing
• Location and dimensions of flashing reglets
grooves
• Coordination of waterproofing system require-
ments with structural system expansion/provisions
• Special details around special penetrations

10. Interior finishes

• Floors, walls, and ceilings
• Joints between precast concrete members for
direct-carpet overlay
• Visual appearance of joints for exposed ceilings
• Fit-up details to ensure good appearance of
interior corners
• Appearance of cast-in-place to precast con­
crete interfaces

11. Interior walls and partitions

• Clearance for prefabricated cabinetry
• Interfacing of mating embedded conduit runs
 
13

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